Oriented high density polyethylene film, compositions and process suitable for preparation thereof

ABSTRACT

The draw ratio and/or rate of stretch of HDPE in film orientation can be increased, or the breakage frequency at a given draw ratio and draw rate decreased by the addition of an orientation improving amount of a normally solid fatty carboxylic acid having a melting point lower than the orientation temperature of the film.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention pertains to oriented film of high densitypolyethylene, to compositions suitable for the preparation thereof, andto a process for its preparation.

[0003] 2. Background Art

[0004] Polyethylene is available in numerous forms required of thevarious and distinct end uses for which it is destined. Polyethylene maybe roughly divided into low density and high density grades. Within eachgrade, polyethylene may exhibit a variety of melt temperatures, meltflow ratios, melt viscosities, and the like. The physical properties ofeach type of polyethylene must be closely tailored to the specific enduse; otherwise processing becomes problematic or even impossible. Thus,it is impossible, in general, to employ a polyethylene compositiontailored for one type of processing in another type of processing. Forexample, low density polyethylene (LDPE) is widely used for preparationof films, and finds uses in such items as cargo wrap and plastic refusebags. LDPE is relatively easy to formulate for such uses, and maycontain numerous ingredients in addition to LDPE itself, i.e., pigments,UV absorbers, thermal stabilizers, plasticizers, lubricants, etc.

[0005] Oriented high density polyethylene (HDPE) is an altogetherdifferent product, and is formulated differently than its LDPE relative.By orienting HDPE, the strength and stiffness properties are markedlyimproved. As a result, stronger, and optionally thinner films may beprepared. The higher density and, in general, different physicalproperties of HDPE require different processing considerations, andorientation adds additional complexity. Oriented HDPE is generallyextruded as a film, and water quenched. Films may also be chill rollcast, or blown and air quenched. The film is then uniaxially orbiaxially stretched, optionally followed by annealing. The stretchingoperation takes place below the melt temperature, and may be termed a“hot stretch.” The stretching operation must take place without anysubstantial likelihood of breakage, as breakage requires that the entireorientation process be restarted, increasing process down-time andgreatly increasing cost.

[0006] A variety of different types of HDPE may be successfully orientedas film, and such HDPE is commercially available. However, oriented filmproduced from such compositions is not necessarily optimal for certainapplications, and thus improvements in HDPE oriented film are desirable.Moreover, up till now, solution processed HDPE has proven to beextremely difficult to prepare as oriented film. Solution-polymerizedHDPE is prepared by polymerizing ethylene in solution, following whichthe solvent is removed and the polymer is pelletized.Solution-polymerized HDPE tends to stretch inconsistently, and thus therate and/or amount of stretch must be decreased in order to orient thefilm without breaking, if orientation can be performed at all.Decreasing the amount of stretch generates a product having differentand generally less desirable physical properties, while decreasing therate of stretch results in increased production time and cost.

SUMMARY OF THE INVENTION

[0007] The present invention pertains to an HDPE composition containinga normally solid, long chain carboxylic acid having a melting pointbelow the orientation temperature of the HDPE film. The compositions,even when employing solution-polymerized HDPE, have been found tostretch at commercially useful rates and stretch ratios without unduebreakage. For HDPE which can be stretched without additives, adding longchain carboxylic acids lowers further the already low frequency ofbreakage occurring during commercial manufacturing processes, and mayresult in higher physical properties as a result of greater uniformityin the stretching operation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0008] The HDPE used in the present invention is that conventionallyrecognized as HDPE by the skilled artisan, i.e., polyethylenehomopolymers or copolymers having a density of from 0.94 to 0.965. Ingeneral, copolymeric HDPE contains 20 weight percent or less,particularly 10% by weight or less of copolymerizable comonomers.Suitable comonomers are well known in the art, with preferred comonomersbeing butene, hexene, and octene. The polyethylene may be made byconventional catalysts, i.e., of the Ziegler-Natta type, or may be madeemploying a wide variety of single site catalysts, for example STAR™ethylene polymerization catalysts developed by EQUISTAR, Cincinnati,Ohio. Processes for preparing HDPE include all those in common use,including gas phase, slurry, and solution processes. Solution processedpolyethylene is the preferred polyethylene in the present application.The resultant polyethylene, optionally including thermal and/or UVstabilizers, is commonly extruded and pelletized to form a polyethylene“raw material”.

[0009] The HDPE polyethylene raw material is extruded through a die intofilm. Prior to or while in the extruder, the HDPE raw material iscompounded with any additional ingredients, generally including dyesand/or pigments, thermal and/or UV stabilizers, etc. These may be dosedinto the extruder by themselves, or in master batches of HDPE containinglarger than desired amounts of additives. Alternatively, master batchescontaining the desired ingredients may be mixed in the appropriateproportions with the HDPE raw material prior to entry into the extruder.The HDPE preferably contains no fillers, especially fillers which wouldcause disruption of the film such as the formation of voids.

[0010] In the present invention, the ability to stably orient extrudedpolyethylene films is induced or augmented by the addition of a smallquantity of a normally solid carboxylic acid, one having a melting pointbelow the film orientation temperature, preferably stearic acid,palmitic acid, or mixtures thereof, and most preferably, palmitic acidalone. Other low melting but normally solid fatty carboxylic acids maybe used as well, one example being lignoceric acid. While the fattycarboxylic acids may contain ethylenic unsaturation, they must benormally solid, i.e. solid at 25° C. Thus, numerous common unsaturatedfatty acids such as oleic acid, linoleic acid, and linolenic acid arenot suitable for use herein, although they may find themselves useful aslubricants or plasticizers in very small amounts. The preferred fattyacids are saturated fatty acids, most preferably linear fatty acids suchas occur in natural products, preferably natural products of vegetableorigin.

[0011] The manner in which the normally solid, low melting fatty acidfunctions is not known with certainty. Without wishing to be bound toany particular theory, it is presently believed that the long chainfatty acids, having a structure similar to polyethylene, is able to behomogeneously dispersed in the polyethylene, where it functions to allowgreater mobility between adjacent polyethylene polymer chains. Thegreater mobility is thought to reduce the inconsistencies otherwiseassociated with the orientation of polyethylene polymers.

[0012] The amount of solid, fatty acid is an amount effective to alloworientation without undue breakage, while maintaining desirable endproperties. The actual amount is dependent to some degree on theparticular HDPE, and thus may vary. However, the amount is virtuallyalways less than 1% by weight (10,000 ppm), more preferably from about200 ppm to 5,000 ppm, yet more preferably between 500 ppm and 3,000 ppm,and most preferably about 2,000 ppm, these weights in parts per millionbased on the sum of the weights of the polyethylene and the carboxylicacid in the finished composition. It should be noted that in addition tofacilitating orientation, many of the properties of the oriented filmare improved as well.

[0013] The solid, fatty acid is preferably supplied as a master batch,dispersed in the same or another HDPE. In certain circumstances, LDPE,LLDPE or other polyethylene homopolymers or copolymers may be introducedas well. Preferred master batches contain stearic acid or palmitic acidat a level of from 1 weight percent to 5 weight percent, preferably 1weight percent to 3 weight percent, and most preferably 1.5 to 2.5weight percent. The polyethylene used in the master batch may be thesame or different from the polyethylene to which the master batch willbe added, but is preferably the same or substantially similar. Suitablebase resins include, in a non-limiting sense, the Alathon® polyethyleneresins manufactured by Equistar Corporation, including L5845 with a meltindex of 0.45 and density of 0.958 g/cm³; L5045, with a melt index of0.45 and a density of 0.950 g/cm³; LT618072, with a melt index of 1.0and a density of 0.960 g/cm³; PE4829, with a melt index of 0.34 and adensity of 0.944 g/cm³; and L5885 with a melt index of 0.85 and adensity of 0.958 g/cm³. These are illustrative and not limiting.

[0014] The master batches are generally prepared conventionally in asingle screw or twin screw extruder, although other devices such asHenschel mixers, Banbury mixers, Brabender mixers and other mixers mayalso be used. The carboxylic acid is generally mixed in at relativelylow shear, and thus for a resin with a melt temperature below 285° F.(140° C.), temperatures of 360° F. (182° C.) to 400° F. (204° C.) aresuitable, although higher or lower temperatures may be used as well. Themaster batches preferably contain no stearates such as zinc stearate.Following mixing, the master batch is generally granulated.

[0015] The master batch is added to the desired HDPE in an amountsufficient to provide the necessary resistance to breaking during filmorientation, for example 2,000 ppm relative to the final HDPE product.The HDPE is extruded into film and generally quenched by conventionalprocessing methods, i.e. by chill rolls, air quenching, water quenching,etc. Following film preparation, the film may optionally be slit, i.e.,for forming tape, and is uniaxially or biaxially oriented. Theorientation takes place at a temperature which is preferably above theline drawing temperature, and below the melt temperature. If necking canbe tolerated, lower temperatures may be used.

[0016] The term “line drawing temperature” refers to the temperatureabove which uniform orientation is obtained, as is known in the art. Theline drawing temperature and melting temperature can be determinedexperimentally. When the film is stretched at temperatures low enoughfor line drawing, a “line” or “neck” develops in the film, perpendicularto the direction of stretch once the yield point has been reached.Stretching then starts from this thinned-out region until an elongationequal to the natural stretch ratio of the film is achieved, for theparticular stretch rate used. If a series of film samples is stretchedunder conditions of line-drawing at a set of increasingly highertemperatures, starting at room temperature, a series of decreasinglysharp maxima will result in the corresponding stress-strain curves. Atsome higher temperature, a maximum no longer appears in thestress-strain curve, and line drawing has ceased. At this temperature orhigher temperatures, the film undergoes more uniform stretching over itslength and no longer displays a line or neck during elongation. A moredetailed discussion may be found in “Polyethylene” by Renfrew andMorgan, 2d edition, pages 170-2, published in 1960 by IntersciencePublishers, Inc. New York.

[0017] The line-drawing temperature can change. For example, a film hasa given line drawing temperature before stretching. However, afterstretching in one direction, e.g., the machine direction, theline-drawing temperature of the film in the direction perpendicular tothe direction of stretch, e.g., the transverse direction, is higher thanthe given temperature. This difference in temperatures should be takeninto consideration in order to provide biaxial stretching at the properstretching temperature when stretching in the machine direction andtransverse stretching are not performed simultaneously.

[0018] The stretching may occur in conventional devices, i.e., between aseries of pairs of counter-rotating rollers, the temperature of whichmay vary from roll-to-roll. The initial pair of counter-rotating rollersrevolve at a lower rate than the last pair, or “exit rollers,” withpairs of rollers inbetween revolving at intermediate rates. Thus, theexit speed of the film is higher than the input speed and the film isstretched accordingly. The term “stretch ratio” is the ratio of a lengthof a sample of the film in the orientation direction, after stretching,compared to the original length of the film in the orientationdirection, before stretching. The “stretch rate” is the rate of changein length of the stretched film over time. The stretch ratio may beadjusted to the desired level, i.e., one which achieves the desiredtensile strength, generally a stretch ratio between 3 and 6, morepreferably between 3.5 and 5, and most preferably in the range of 4.0 to4.5, by increasing the relative differences in revolving rates of theinput and exit rollers.

[0019] The optimum temperature for stretching will depend on theparticular polyethylene or blend of polyethylenes selected. Asindicated, when stretching the films, it is necessary for the filmtemperature to be below the melt temperature point and above the linedrawing temperature. In practice, the actual sheet or film temperatureis not usually measured. Instead, what is measured is, for example, thetemperature of the fluid used to heat orienting rolls in a machinedirection orienter, or the air temperature in a tenter frame oven.

[0020] For example, the rollers may be contained within a stretch oven,which is preferably maintained at a temperature above the melttemperature of the polyethylene. Because of the speed of travel of theweb through the oven, however, the film temperature never rises abovethe melt temperature, and thus the stretching takes place in the solidstate. The orientation temperature may be up to just less than the melttemperature, generally about 130° C., but is preferably below 125° C.,more preferably in the range of 80° C. to 120° C., and most preferably100° C. to 115° C.

[0021] If biaxial orientation is desired, the film is not slit prior tostretching (but may be slit afterwards), and enters the oven in a tenterframe, as shown in FIGS. 2 and 3. A series of clamp-like devices clamponto the edges of the film and move apart relative to each other both inthe transverse and lateral directions. The film is thus stretched bothacross its width (transverse) and along its length (laterally). Thestretch ratio may be the same or different in these directions. Acombination of roller stretching (monoaxial) and transverse stretchingin a tenter frame may also be employed, or any combination. Followingstretching, whether monoaxial or biaxial, the resulting film or tape isoptionally annealed in the annealing oven. Following exit from theoptional annealing oven, the product may be wound onto rolls or bobbins(i.e., for tape), may be woven, and/or laminated to other films. Thetape may be woven into woven products. The oriented product has hightensile strength due to the stretching operation below the melttemperature, and is a coherent product, for example exhibiting a lack ofmicrovoids.

[0022] Having generally described this invention, a furtherunderstanding can be obtained by reference to certain specific exampleswhich are provided herein for purposes of illustration only and are notintended to be limiting unless otherwise specified.

EXAMPLE 1 AND COMPARATIVE EXAMPLES C1-C4

[0023] A master batch of 2 weight percent palmitic acid in asolution-type polyethylene homopolymer (Alathon® L5885 polyethylene)with a melt index of 0.85 and a density of 0.958 is preferred, by mixingthe ingredients under low shear at 360° F. to 400® F. until a homogenousproduct is obtained. The master batch is then extruded and pelletized.Films of Alathon® L5885 polyethylene base resin with and withoutpalmitic acid derived from the master batch are air blown and quenched.The properties of the films as prepared (non-oriented), and at stretchratios of 4:1 and 5:1 are measured. The results are presented inTable 1. TABLE 1 Example C1 C2 C3 C4 1 Palmitic Acid 0 0 0 2000 2000Film Type Not Oriented Oriented 4:1 Oriented 5:1 Not Oriented Oriented5:1 Gauge (mil) 4.13 1.1 0.92 4.02 1.0 Dart Drop (F50) 183 <36 <36 186<36 Elmendorf Tear 80/440 6/Breaks MD 5/410 78/440 5/350 (MD/TD)¹ Gloss(units) 5.9 17 23 5.8 30 Haze (%) 81 54 44 81 34 1% Secant Modulus151340/203960 258590/258590 346170/281540 148500/198030 360660/274570(psi) (MD/TD) Puncture (Newtons) 91.1 13.2 9.7 94.3 13 TEDD 1.5 0.440.44 1.5 0.52 Yield (psi) (MD/TD) 4290/4850 15600/4400 28400/39204210/4630 30300/3040 Elongation at Yield 10/5 20/3 19/2 11/5 19/2 (%)(MD/TD) Break (psi) 5970/4220 17100/2520 20800/3320 6330/5510 23600/3290(MD/TD) Elongation at Break 740/640 110/15 36/6 790/980 31/4 (%) MD/TDWVTR (g/m²/day) 0.76 1.84 2.19 0.64 2.22

[0024] The results presented in Table 1 illustrate the improvement inorientation obtainable through use of the low melting, normally solidfatty acids of the present invention. Particularly noteworthy is thedecrease in haze, the increase in elongation at yield, and the tensilestrength at break. The amount of haze is related to the ability of thefilm to stretch uniformly. The greater the uniformity, the less haze.Solution processed polyethylene, for example, stretches inconsistently,producing considerable haze. Products with less haze are also viewedmore favorably by the purchaser. The addition of only 2000 ppm palmiticacid lowered the relative amount of haze by approximately 25 percent.

[0025] At the same time, the tensile strength at break in the machinedirection is increased by ca. 10%, even though the film is slightlythinner (1.0 mil versus 1.1 mil). This increase in breaking strength,and the improvement in haze, are accomplished without significantlyaffecting other properties such as elongation at yield or Elmendorf tearstrength. The puncture strength shows significant improvement as well.

[0026] A further indication of the ability of the low melting, normallysolid fatty acids of the subject invention to improve processing is the“TM Long” Test, a non-standard test where necking-in is prevented bymaintaining the edges of the film at a fixed distance duringlongitudinal stretch. This test is particularly sensitive, and allowsobservation of effects which less sensitive tests do not.

EXAMPLES 2. C5 AND C6

[0027] Films of Alathon® L4903 polyethylene resin with a density of0.949 and a melt index of 0.027 was oriented using the “TM Long” testdescribed above. In the comparative example, no processing aid wasadded. In the subject invention example, 2000 ppm palmitic acid wasincluded in the formulation. The results are presented in Table 2 below.The orientation was performed at 110° C. TABLE 2 Palmitic Draw DrawExample Acid Ratio Rate Comments C5 None 4.0:1 70 mm/s Broke C6 None4.0:1 40 mm/s OK 2 2000 ppm 4.0:1 70 mm/s OK

[0028] The results in Table 2 indicate that the HDPE with no processingaid could be stretched at a draw ratio of 4.0:1 and a draw rate of 40mm/s. However, at a higher draw rate of 70 mm/s, the film broke. Byadding 2000 ppm palmitic acid, the film could be satisfactorilystretched at a draw rate of 70 mm/s.

[0029] While embodiments of the invention have been illustrated anddescribed, it is not intended that these embodiments illustrate anddescribe all possible forms of the invention. Rather, the words used inthe specification are words of description rather than limitation, andit is understood that various changes may be made without departing fromthe spirit and scope of the invention.

What is claimed is:
 1. In a process for the orientation of high densitypolyethylene (HDPE) film containing conventional additives by stretchingan HDPE film at an orientation temperature below the film's melttemperature, the improvement comprising: adding to the HDPE prior topreparing said film, a normally solid fatty carboxylic acid having amelting point lower than said orientation temperature, in an amount offrom 0.02 weight percent to about 1 weight percent, said weight percentsbased on the sum of the weights of HDPE and fatty carboxylic acid insaid film, said HDPE being substantially free of filler such thatfiller-created microvoids are substantially avoided.
 2. The process ofclaim 1, wherein said fatty carboxylic acid is selected from fattycarboxylic acids having melting points between 60° C. and 100° C.
 3. Theprocess of claim 1, wherein metal stearates are absent from saidcomposition.
 4. The process of claim 2, wherein said fatty carboxylicacids are selected from stearic acid, palmitic acid, lignoceric acid,and mixtures thereof.
 5. The process of claim 2, wherein said fattycarboxylic acid is palmitic acid.
 6. The process of claim 3 wherein saidfatty carboxylic acid is palmitic acid.
 7. The process of claim 1,wherein said HDPE is one which cannot be stretched without breakage atthe same draw ratio and draw rate, but the same HDPE with the additionof said fatty carboxylic acid can be stretched at said draw rate anddraw ratio.
 8. The process of claim 1, wherein said orientationtemperature is below 120° C.
 9. The process of claim 1, wherein saidorientation temperature is below 115° C.
 10. A substantiallymicrovoid-free oriented HDPE film having a draw ratio in excess of 3,said film free of metal stearates, and comprising a) HDPE having adensity from 0.94 to 0.965 g/cm³, and b) from 0.02 to 1 weight percentof a normally solid fatty carboxylic acid having a melting point belowthe temperature at which said film was oriented, said weight percentrelative to the sum of a) and b).
 11. The film of claim 10, wherein saidfatty carboxylic acid is selected from fatty carboxylic acids havingmelting points between 60° C. and 100° C.
 12. The film of claim 10,wherein said fatty carboxylic acids are selected from stearic acid,palmitic acid, lignoceric acid, and mixtures thereof.
 13. The film ofclaim 10, wherein said fatty carboxylic acid is palmitic acid.
 14. Thefilm of claim 10, wherein said orientation temperature is below 120° C.15. A master batch for addition to HDPE to increase the amount or rateof stretch without breakage or to decrease the frequency of breakage ata given amount and rate of stretch, said master batch being free ofmetal stearates, and comprising HDPE or a mixture of HDPE and anotherpolyethylene homo- or co-polymer of lower density, and from 1 to about 5weight percent of a normally solid fatty carboxylic acid having amelting point less than 100° C.